Removal and Replacement
WM 343519 Removing and installing transmission
Tools
Technical values
Preliminary work for transmission
1. Disconnect the battery. -> 270619 Removing and installing battery Removal and Replacement
2. Remove underbody panelling at the front/centre. -> 519319 Removing and installing cover for centre underbody Service and Repair
3. Remove front cardan shaft. -> 390219 Removing and installing front cardan shaft 390219 Removing and installing front cardan shaft
Removing transmission
1. Disconnect cables on the transmission. To do this, lever off ends of cables using disassembly tool Nr.21 ( -2- ) and remove the locking element -1-.
Cable connection on transmission
2. Remove rear cardan shaft on the transfer gear. To do this, press off the cardan shaft using a mounting lever.
Removing cardan shaft from transfer gear
3. Tie up the cardan shaft in the centre tunnel.
4. Disconnect exhaust system at the transmission support -2- and cross member -1-.
Screw points for exhaust system
5. Unscrew fastening screw for clutch slave cylinder -arrow- and leave it hanging to one side.
Clutch slave cylinder
6. Place a suitable wooden block under the transmission bell housing.
Supporting transmission
7. Support the transfer gear with engine and gearbox jack V.A.G 1383 A WE 1082.
8. Unscrew four fastening screws for securing the transmission cross member to the body -1-.
Transmission cross member
9. Unscrew two fastening screws used to secure the transmission cross member to the holder -2- and remove the cross member.
Transmission cross member
10. Remove exhaust system holder at the transmission bell housing -inset-.
Screw points for exhaust system
11. Unplug cable plug on the transfer gear control unit.
Transfer gear control unit
12. Lower the transmission onto the wooden block.
Supporting transmission
13. Unscrew fastening screws for transfer gear.
Transfer gear screws
14. Remove transfer gear.
15. Unplug cable plug for neutral switch at the top of the shift cover.
Neutral switch
16. Unplug cable plug for reversing light switch.
Reversing light switch
17. Disconnect coolant line at the side of the transmission.
Coolant pipe on transmission
18. Remove transmission vent line at the top of the transmission.
Transmission vent line
19. Detach line bracket for B+ line.
Holder for B+ line
20. Remove the starter. ->
21. Mounting plate 9725 must be secured to the manual transmission.
Mounting plate on transmission
22. Support the transmission with engine and gearbox jack V.A.G 1383 A WE 1082 -1- and secure with a retaining strap -2-.
Engine and gearbox jack + transmission
23. Unscrew fastening screws for securing transmission to engine. To do this, unscrew four screws on the engine side and seven screws on the transmission side.
Transmission flange
24. Remove transmission.
Installing transmission
1. Mounting plate 9725 must be secured to the manual transmission.
Mounting plate on transmission
2. Support the transmission with engine and gearbox jack V.A.G 1383 A WE 1082 -1- and secure with a retaining strap -2-.
Engine and gearbox jack + transmission
3. Run in transmission.
4. Screw in fastening screws for securing transmission to engine. To do this, screw in and tighten four screws on the engine side and six screws on the transmission side.
Transmission flange
5. Place a suitable wooden block under the transmission bell housing.
Supporting transmission
6. Mounting plate 9725 can now be removed from the manual transmission.
Mounting plate on transmission
7. Install the starter.
8. Screw in line bracket for B+ line.
Holder for B+ line
9. Fit vent line on the transmission.
Transmission vent line
10. Attach cable plug for reversing light switch.
Reversing light switch
11. Plug in cable plug for neutral switch at the top of the shift cover.
Neutral switch
12. Install transfer gear. To do this, screw in the fastening screws. => Initial tightening: 20 Nm (15 ftlb.) => Final tightening: 90°
Transfer gear screws
Information
Always observe the exact work sequence when installing/removing the transmission cross member.
Information
Always observe the exact work sequence when installing/removing the transmission cross member.
Information
- Screws which are tightened with a torque angle must be replaced with new ones.
13. Screw in two fastening screws -2- for securing the transmission cross member to the holder on the transfer gear. => Initial tightening: 50 Nm (37 ftlb.) => Final tightening: 90°
Transmission cross member
14. Screw in four fastening screws -1- for securing the transmission cross member to the body. => Initial tightening: 50 Nm (37 ftlb.) => Final tightening: 90°
Transmission cross member
15. Insert clutch slave cylinder and screw in fastening screw. => Tightening torque: 10 Nm (7.5 ftlb.)
Clutch slave cylinder
16. Secure coolant line at the side of the transmission. => Tightening torque: 10 Nm (7.5 ftlb.)
Coolant pipe on transmission
17. Plug in cable plug on the transfer gear control unit.
Transfer gear control unit
18. Install exhaust system holder -inset-. => Tightening torque: 23 Nm (17 ftlb.)
Screw points for exhaust system
19. Replace circlip -1- and O-ring -2- on transfer gear flange.
Circlip on flange
20. Fit rear cardan shaft on the transfer gear. To do this, slide the cardan shaft onto the flange until it engages securely.
21. Press ends of cables -2- onto the ball heads of the external shift mechanism and fit locking elements -1- on the support.
Cable connection on transmission
Subsequent work for transmission
1. Install front cardan shaft. -> 390219 Removing and installing front cardan shaft 390219 Removing and installing front cardan shaft
2. Install underbody panelling at the front/centre. -> 519319 Removing and installing cover for centre underbody Service and Repair
3. Connect the battery. -> 270619 Removing and installing battery Removal and Replacement